Apparatus for positioning in-wall power

ABSTRACT

The present invention discloses a method and apparatus for locating a pre-wired electrically isolated power source. The invention includes a plurality of embodiments of encased receptacles that are rearward mountable to recessed electrical enclosures.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.61/516,768 filed 7 Apr. 2011, U.S. Provisional Application No.61/630,677 filed 16 Dec. 2011, and U.S. Utility application Ser. No.13/506,136 filed 29 Mar. 2012.

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for locating apre-wired electrically isolated power source. The invention includesembodiments of encased receptacles for positioning in-wall power.

BACKGROUND OF THE INVENTION

Providing electrical power behind a wall structure currently requiresthe use of a standard electrical receptacle and wiring to be mountedinternal to an electrically isolated box to prevent access to theinternal wiring. Typically, an electrician is required to complete theinstallation which requires connecting into existing power and locatingthe new electrical receptacle and box.

The electrical box includes a cover plate flush mounted to the exteriorwall leaving an opening for the power receptacle.

More recently, some electrical appliances, particularly flat screentelevisions, are mounted directly to the wall, so that externallyconnected plugs protruding out of the wall plate interfere with mountingthe television in flat abutment with the surface of the wall.

There exists a need for an apparatus for positioning in-wall power whichcan be accomplished by a lay person without the need of an electrician,and which provides electrically isolated receptacles, that arepre-wired, which can be mounted either external to an electrical box,thereby creating space internal to the wall for isolating plugs andconnectors, or directly to a wall when recessed receptacles are notnecessary.

SUMMARY OF THE INVENTION

The foregoing and other problems are overcome, and other advantages arerealized, in accordance with the disclosed, alternative embodiments ofthese teachings.

The power solution of the present invention comprises pre-wiredelectrically isolated female and male receptacles combined with anintegrated enclosure that can be used in applications where power mustbe supplied to a remote unit, such as a flat panel TV being hung on awall (behind wall installation), or in a remote location where anintegrated enclosure is necessary for installation and electricalisolation (trade show/outdoor exhibit where remote power is utilized ona temporary wall fixture).

For behind wall installations the invention may be combined with “DeepBox” mounting enclosures. The “deep box” enclosures allow for the inputand output receptacles of the present invention to be mounted deepinside a wall for visual isolation of receptacle outlets and associatedplugs/connectors that may also be present in the enclosure.

In a behind wall installation, the integrated enclosures containing thefemale and male receptacles are separated behind a wall such that powercan be supplied to the female end from an external source (such as anextension cord) which will supply power to a male receptacle mountedinterior to the wall. The integrated enclosures for the receptacles arenecessary to facilitate mounting in a variety of forms. Both the powerinput (female end) and power output (male end) integrated enclosures maycontain a mounting frame for installation directly to a wall surface oronto any type of faceplate or in-wall enclosure, such as the “deep box”mounting enclosures of the present invention.

Alternatively, the integrated enclosures may be sold pre-mounted to anyin-wall enclosure, including the “deep Box” enclosures disclosed in thepresent invention. Further, the integrated enclosed receptacles,interface wiring, and associated mounting frames or boxes (deep box orconventional electrical box) may be sold as a kit to facilitate easyinstallation. The electrical connection between the integratedenclosures may be separable via a snap plug or the like.

The integrated enclosures facilitate mounting of the power output andpower input to a variety of electrical boxes including standardelectrical boxes, flush mounted wall plates, and “deep boxes” disclosedin the present invention. Since the receptacles are encased andpre-wired, they are not required to be mounted internal to an electricalbox for electrical isolation. This allows for the receptacles to bemounted externally to the electrical box enclosure, creating additionalspace within the box necessary for hiding connectors and the like. Theencased receptacles may also be rough mounted to any wall surface.

The power input and power output integrated enclosure may be formed byovermolding, be a one piece boot, a two piece joinable encasement, ormay comprise an integrated enclosure built around an overmoldedconnector. The receptacles are electrically connected within theintegrated enclosure at the factory (pre-wired) and the electricalcoupling between the enclosures can be ordered in specific lengths tomeet the needs of a particular installation.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the present invention areexplained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1 illustrates an embodiment employing the principles of subjectinvention denoting encased receptacles as encased power input and poweroutput with an electrical interface as any length necessary for aparticular installation.

FIG. 2 illustrates the embodiment of FIG. 1 having faceplates forconnection to the encased receptacles.

FIG. 3 illustrates the embodiment of FIG. 2 illustrating theinstallation of the encased receptacles, electrical interface, andfaceplates in a wall. Also illustrated is an existing power receptaclewith an extension cord for routing available power to the encased powerinput receptacle via an extension cord.

FIG. 4 illustrates an alternative embodiment for the design of theencased receptacles 10 and 20.

FIG. 5 illustrates a perspective view of the encased receptacle of FIG.2.

FIG. 6 illustrates a boot used to encase a receptacle.

FIGS. 7-9 illustrate an encased receptacle of the present invention incombination with a recessed electrical box.

FIG. 10 illustrates an encased receptacle of the present invention incombination with a recessed electrical box mounted to a wall.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While certain embodiments of the present invention have been illustratedand described herein, the present invention should not be limited tosuch illustrations and descriptions. It should be apparent to thoseskilled in the art that changes and modifications may be incorporatedand embodied as part of the present invention and are within the scopeof the claims.

As seen in FIGS. 1-4, the integrated enclosure in the form of an encasedpower output 10 and encased power input 20 are illustrated as connectedby an electrical coupling 15. Coupling 15 contains the electricalconnections between power input 20 and power output 10, and may includesolid copper conductors and combinations of hot, neutral and groundconductors encased in any electrical interface conduit as required byapplicable building codes. FIG. 5 illustrates the encasement structurethat applies to both the power input and power output.

The assembled In-Wall power apparatus 30 is purchased for particularapplications with a fixed length electrical coupling 15. In thealternative, encased power input 20 and power output 10, can eachcontain a fixed length electrical coupling to be connected on-site. Eachcoupling may be a mating connector or bare wire to be connected duringinstallation. Such an embodiment would facilitate selling componentsseparately. The encased receptacle embodiment (both power input andpower output) and coupling 15 are electrically insulated and pre-wiredto meet applicable building codes and further to be installed by alaymen without the need for a licensed electrician.

As illustrated in FIGS. 1,2, and 5 the encased receptacles 10 and 20further include mounting frames 60A. The frames may be overmolded, orexternally affixed to receptacles 10 and 20. The mounting frames 60Ahave a first end 60A1 affixed to the receptacles 10 and 20 and a secondend 60A2 that includes tabs 25 including tab connection holes 25A, 25B,25C, and 25D. Although connection holes 25A-25D are disclosed otherconnection holes could be included in tab 25. The selection of holes25A-25B in the embodiment of FIG. 1-4 is to illustrate the utilizationof faceplates 35 and 40. Other mounting frames and tab configurationsmay be utilized to meet specific installation requirements. Encasedstandard NEMA, standard duplex, and non-standard custom receptaclesrequire different dimensioned mounting frames and tabs.

FIG. 3 illustrates the power apparatus 30 of the present inventionaffixed to the surface of an exterior wall 45. In the present example, ahole would be cut in the wall for placement of receptacle 10 in anelevated location on the wall 45. Even without installing decorativefaceplates 35 and 40, the receptacles 10 and 20 can be installed, as is,in wall 45 by screwing or nailing into the receptacles 10 and 20 viaholes 25-thru 25D into wall 45. First, two holes would be made in wall45. Next, Receptacle 20 would be “fished” down to the first hole andreceptacles 10 and 20 would be secured within the openings. Preferably,receptacle 20 would be at floor level out of view and in the vicinity ofa live power outlet 50 as illustrated in FIG. 3. Live power would thenbe supplied to receptacle 20 via a conventional extension cord 55. Powerwould then be available to receptacle 10 for powering, for example, aflat panel TV (not shown) mounted over receptacle 10.

For a more decorative installation, faceplate 40 could be placed withinthe opening, connected to receptacles 10 and 20 via screw or nailsthrough holes 25D and 40A, then faceplate 35 could be placed overreceptacles 10 and 20 and connected over faceplate 40, via screws ornails through holes 35A and 25B. Receptacles 10 and 20 would beaccessible through opening 35B of faceplate 35.

Referring to FIG. 2 and FIG. 5, and in the preferred embodiment, encasedreceptacles 10 and 20 include a front face 130 having a top 130A, abottom 130B, and left and right side surfaces 130C and 130D. These sidesurfaces 130A, 130B, 130C and 130D extend rearward to an orthogonal lipextension surface 132 that defines a peripheral edge adjacent to top130A, bottom 130B, and left and right side surfaces 130C and 130D. Asillustrated in FIG. 5, mounting frame 60A first end 60A1 issubstantially coplanar with orthogonal lip extension surface 132. Asillustrated in FIG. 2, the peripheral edge 35B1 of faceplate 35, whenengaged with receptacles 10 and 20, will rest on lip extension surface132 to facilitate a flush coplanar mounting arrangement between frontface 130 and faceplate 35 front surface 35B2.

FIG. 4 illustrates an alternative embodiment for the design of theencased receptacles 10 and 20.

In an alternative embodiment a molded boot 90 (FIG. 6) can be used tocreate an encased receptacle. In the above example, the boot 90 could besubstituted for housing 75 in glued or sealed contact with mountingframe 60 of receptacle 100. As illustrated in FIG. 6, the boot 90 wouldinclude a rearward aperture 90A for routing interface coupling 15.

Other configurations of installations are possible, as described herein,such as recessed power input and power output within a walls interiorsurface.

An alternative application of the encased receptacles 10 and 20 is incombination with recessed electrical boxes 120 and is illustrated inFIGS. 7-10. It is understood that all embodiments of encased receptacles10 and 20 described herein are mountable to all embodiments of therecessed electrical boxes described herein.

Referring to FIG. 7, the single gang recessed electrical box 120includes an integrated face plate 122 with a flange 122B that extendsoutward beyond the periphery of box 120A. The box 120 includes wallmounting claws 124 that are adjustable to engage drywall or the like viapositioning screws. The box includes connection apertures 120B forsecuring any of the various embodiments of encased receptacles discussedherein. Opening 120C includes peripheral edge 120C1 and is approximatelydimensioned to slideably engage the top 130A, bottom 130B, and left andright side surfaces 130C and 130D of receptacles 10 and 20 to a pointwhen orthogonal lip extension surface 132 rests against the rear surface120C2 of box 120A.

Since the electrical receptacles are electrically isolated and pre-wiredin one of the various forms described herein, they can be mountedexternal to recessed electrical box 120, as illustrated in FIGS. 8-10.This creates a deep opening within the wall, as illustrated in FIG. 10,and a receptacle face 130 in a flush mounted coplanar relationship withelectrical box 120 interior surface 120C3 (FIG. 9).

As illustrated in FIG. 9, a larger front opening 120D is of sufficientlength and width to allow access to the mounted receptacles 10 locatedinward of opening 120D. As illustrated in FIG. 10, in the field, a holewould be cut in the wall at a dimension less than the periphery of faceplate 122, flange 122B. Utilizing the engagement claws 124 against theinterior wall mounting surface 45B by turning the positioning screws122A, the claws would force the Flange 122B against the wall for asecure fit.

I claim:
 1. A power feed device, comprising: An encased power input incommunication with a mounting frame disposed thereon, said power inputfor receiving electrical power supplied thereto; An encased power outputin communication with a mounting frame disposed thereon, said poweroutput for delivering power to an electrical device; said encased powerinput and power output having an electrical interface therebetween, saidpower input and power output mounting frames for positioning said powerinput and said power output on a wall 1, wherein said encased powerinput and said encased power output are electrically isolated andpre-wired within said encasements.
 2. A power feed device as in claim 1,wherein said encased power input has a front face substantially coplanarwith said encased power input mounting frame and said encased poweroutput has a front face substantially coplanar with said encased poweroutput mounting frame.
 3. A power feed device as in claim 1, whereinsaid electrical interface comprises solid copper conductors.
 4. A powerfeed device as in claim 1, wherein said electrical interface furthercomprises a mating connector, said mating connector for disconnectingand connecting said electrical interface.
 5. A power feed device as inclaim 1, wherein said received electrical power is supplied to saidpower input through an extension cord, said extension cord receivingpower from an external source.
 6. A power feed device for connection toa first and second recessed electrical box, said recessed electrical boxhaving a first opening and a smaller second opening having a peripheraledge, each said first and second electrical boxes having an interiorsurface having sides that project generally rearward from said firstopening up to a rear panel, said rear panel extending inward from eachside of said interior surface, said rear panel comprising the smallersecond opening, said rear panel having a first surface in communicationwith said interior surface and a second surface external to said firstand second electrical boxes, said power feed device comprising: anencased power input in communication with a mounting frame disposedthereon, said mounting frame having a first end integrated into saidencased power input and a second end, said power input for receivingelectrical power supplied thereto; an encased power output incommunication with a mounting frame disposed thereon, said mountingframe having a first end integrated into said encased power output and asecond end, said power output for delivering power to an electricaldevice; wherein said encased power input and encased power outputcomprise a front face having top, bottom, left and right side surfaces,said top, bottom, left and right side surfaces extending rearward to anorthogonal lip extension surface, said top and bottom orthogonal lipextension surfaces including said mounting frame first end in asubstantially coplanar relationship with said orthogonal lip extensionsurfaces; Said front face of said encased power input and encased poweroutput for engagement into said rear panel second opening of said firstand second electrical boxes up to a point when said rear panel exteriorsurface contacts said orthogonal lip extension surface; said encasedpower input and power output having an electrical interfacetherebetween.
 7. A power feed device as in claim 1, wherein saidencasement of said power input and said power output is a boot, saidboot dimensioned to slide over and seal said power input and poweroutput.
 8. A power feed device as in claim 1, wherein said encasement ofsaid power input and said power output is an overmold, said overmolddimensioned to electrically isolate said power input and power output.9. A power feed device comprising: An encased power input incommunication with a mounting frame disposed thereon, said mountingframe having a first end integrated into said encased power input and asecond end, said power input for receiving electrical power suppliedthereto; An encased power output in communication with a mounting framedisposed thereon, said mounting frame having a first end integrated intosaid encased power output and a second end, said power output fordelivering power to an electrical device; wherein said encased powerinput and encased power output comprise a front face having top, bottom,left and right side surfaces, said top, bottom, left and right sidesurfaces extending rearward to an orthogonal lip extension surface, saidtop and bottom orthogonal lip extension surfaces including said mountingframe first end in a substantially coplanar relationship with said topand bottom orthogonal lip extension surfaces; said encased power inputand power output having an electrical interface therebetween.
 10. Apower feed device as in claim 9, further including a faceplate mountedthereon, said faceplate having an opening for access to said power inputand power output, said faceplate including an opening having aperipheral edge, said front face of said encased power input and encasedpower output for engagement into said faceplate opening up to a pointwhen said faceplate peripheral edge contacts said orthogonal lipextension surface.
 11. A power feed device as in claim 1 wherein saidencased power input and said encased power output is selected from thegroup consisting of a standard duplex device, a standard nema device, ora non-standard device.
 12. A kit for positioning remote powercomprising: An encased power input having an electrical extension cut toa specific length; An encased power output having an electricalextension cut to a specific length; Said encased power input and poweroutput adapted to be mounted to a wall.
 13. A kit for positioning remotepower as in claim 12 further including a faceplate for mounting saidpower input and power output flush to a walls surface.
 14. A kit forpositioning remote power as in claim 12 further including at least onerecessed box, said encased power input and encased power outputadaptable for recessed positioning within a wall interior, said powerinput and power output mounted externally to said at least one recessedbox.
 15. A kit for positioning remote power as in claim 12 wherein saidelectrical extensions include a mating plug.
 16. A method of locating apower feed device, comprising the steps of: Cutting a first power inputhole in an exterior wall and a second power output hole in an exteriorwall; Feeding an encased power input, and encased power output, and anelectrical coupling interface, throughout the interior of said wall;Affixing said encased power input in said first power input hole andaffixing said power output in said second power output hole.
 17. Amethod as in claim 16, further including the step of providing power tosaid encased power input.
 18. A power feed device as in claim 1, whereinsaid power input further comprises a male receptacle, said malereceptacle receiving power from an external source, and said poweroutput further comprising a female receptacle.
 19. A power feed deviceas in claim 18, wherein said external source is a powered extensioncord.
 20. A power feed device as in claim 1, wherein said power inputand power output are electrically coupled by hot, neutral and groundconductors.